Fe-Based Amorphous Alloy Dust Core for High Saturation Flux
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Solution Overview
Problem
Existing Fe-based amorphous alloys used in dust cores and choke coils for power supplies struggle to achieve high saturation magnetic flux density while maintaining a glass transition temperature, particularly those in the Fe—Cr—P—C—B—Si system, which limits their magnetic performance.
Innovation Solution
An Fe-based amorphous alloy composition with specific ranges of Cr, P, C, B, and Si content, optimized through the water atomization method, is developed to achieve a saturation magnetic flux density of 1.5 T or higher while maintaining a glass transition temperature, enhancing both magnetic properties and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional Fe-based amorphous alloy compositions are used, then the alloy can be produced with a glass transition temperature, but the saturation magnetic flux density remains below 1.5 T
Solution Approach 1:
The patent applies parameter changes by precisely controlling the compositional parameters of the alloy system. Specifically, it optimizes the content ranges of Cr (0.1-3.0 at%), P (2.0-6.0 at%), C (0.5-2.0 at%), B (0.5-2.0 at%), and Si (2.0-5.0 at%), along with their ratio relationships (P/(C+B) ≥ 0.5, C/(C+B) ≥ 0.3). These compositional parameter adjustments enable the alloy to simultaneously achieve a glass transition temperature and saturation magnetic flux density of 1.5 T or higher, resolving the contradiction between maintaining glassy state and achieving high magnetic density.
2Quantity of substance
If the alloy composition is optimized for high saturation magnetic flux density, then magnetic performance improves, but the glass transition temperature may be lost
Solution Approach 1:
The patent employs composite material principles by creating a multi-element Fe-based amorphous alloy system that combines Fe with Cr, P, C, B, and Si in specific proportions. This composite composition leverages the synergistic effects of different elements: Fe provides high magnetic saturation, Cr enhances corrosion resistance and stabilizes the amorphous structure, P and C contribute to glass formation, B refines the structure, and Si improves soft magnetic properties. The composite nature of this alloy system enables simultaneous achievement of high saturation magnetic flux density (≥1.5 T) and glass transition temperature, resolving the contradiction between magnetic performance and glassy state maintenance.
3Quantity of substance
If existing Fe—Cr—P—C—B—Si-based alloy compositions are used, then some magnetic properties are achieved, but saturation magnetic flux density of 1.5 T or higher cannot be obtained while maintaining glass transition temperature
Solution Approach 1:
The patent applies local quality principles by establishing specific compositional ranges and ratio relationships for each alloying element rather than using uniform or arbitrary compositions. It defines precise content ranges for Cr (0.1-3.0 at%), P (2.0-6.0 at%), C (0.5-2.0 at%), B (0.5-2.0 at%), and Si (2.0-5.0 at%), along with specific ratio constraints (P/(C+B) ≥ 0.5, C/(C+B) ≥ 0.3). These localized compositional optimizations ensure that each element contributes maximally to the overall performance, enabling the alloy to achieve saturation magnetic flux density of 1.5 T or higher while maintaining glass transition temperature, thus resolving the limitation of existing compositions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The optimized alloy composition achieves a high saturation magnetic flux density of 1.5 T or higher, stabilizes the glass transition temperature, and improves corrosion resistance, surpassing the limitations of conventional methods, particularly in dust cores and choke coils.
Implementation Method 1
the Fe-based amorphous alloy is preferably produced by a water atomization method
Implementation Method 2
the Fe-based amorphous alloy has a glass transition point (Tg)
Data Source
AI summary
An Fe-based amorphous alloy of the present invention has a composition represented by formula (Fe100-a-b-c-d-eCraPbCcBdSie (a, b, c, d, and e are in terms of at %), where 0 at %≦a≦1.9 at %, 1.7 at %≦b≦8.0 at %, 0 at %≦e≦1.0 at %, an Fe content (100-a-b-c-d-e) is 77 at % or more, 19 at %≦b+c+d+e≦21.1 at %, 0.08≦b/(b+c+d)≦0.43, 0.06≦c/(c+d)≦0.87, and the Fe-based amorphous alloy has a glass transition temperature (Tg).